Machine for connecting leads of armature coils to commutators



May 2:6 1942. .1. F. cULLlN 2,284,373

MACHINE FOR CONNEGTING LEADS OF ARMTURE COILS TO COMMUTATORS May 25,1942- J. F. cuLLlN 2,284,373

MACHINE FOR CONNECTING LEADS OF ARMATURE COILS T0 COMMUTATORS Filed Nov.22, 1939 s sheets-sheet 2- May 26, 1942. J, F, CULLIN 2,284,373

MACHINE FOR CONNECTING LEADS- OF ARMATURE COILS T0 COMMUTATORS l FiledNov. 22, 1939 3 Sheets-Sheet 3 Patented May 26,1942 Y iran stares..rersn'r oFFlcs MACHINE FOR CONNECTING LEADS OF ARMATURE COILS T0COMMUTATORS Jasper F. Cullin, Detroit'.` Mich., assignor of twothirds toLou Mervis, Lcckhllaven, Pa.

Application November 22, 1939, Serial No. 305,677

s claims. .v (ci. zel-24)' the armature-core and one inner lead and onei" outer lead from each coil are connected to slots in the commutatorsegments which are insulated from one another, and the segments areequal in number to the number of coils or twice the number of the slotsin the armature-core.

In assembling this type the inner or lower leads from the coils arefirst connected to the slots in the commutator segments and insulatedfrom one another between the segments and the coils and thereaftertheupper or outer series of leads are connected to the slots in thesegments and insulation is provided for the leads between the segmentsand the coils.

One object of the invention is to' provide an improved machine forconnecting or assembling the leads on the armature-coils withthecommutator segments, which is simple in construction and can bequickly operated to expedite the assembling operation.

' Another object of the invention iste provide a machine whereby the-connecting operations for the top leads of the coils vwill be expeditedby providing means for connecting'one` series of alternating leads toalternate segments, so that the insulation can be applied to the leadsbetween the segments and the coils, and then connecting the other seriesof alternating leads to thelcommutator segments or bars. Y l

Another object of the invention is to provide a former for the leadsbetween the commutator segments and the coils, which is operableconjointly with the mechanism for connecting the leads to thecommutator. i

Another object of the invention istofprovide a machine for quickly andefficiently connecting the top leads of the armature to the commutatorand cutting off the yexcessive ends of the leads.r

Other objects of theinvention will appear from the detailed description.

The invention consists in the several novel features which arehereinafter set forth and are more particularly defined clusion hereof.

In the drawings: Fig. l is a front elevation of a machine embodying theinvention, parts being shown in section. Fig. 2 is a vertical transversesection taken online 2-2 of Fig. 1. Fig. 3 is a section taken on line 33 of Fig. 4. Fig.' 4 is a plan of a portion of the machine. Fig. 5is aby claims Vat the con;

the commutator is held. Fig. 6 is an end view, partly in section, ofsaid sleeve.v Fig. '7 is a longitudinal section through the mechanismfor rotatably supporting the commutator for the insertion of successiveleads from the'coils of the armature, the inserting blade and former forthe leads being sllownin inoperative position. Fig. 8 is a similarviewillustrating theinserting blade and former for the leads in operativeposition. Fig.9 is a section taken on line 9-9 of Fig. 7. Fig. 10 is a.section on lineV lI-t of Fig. 4.

Fig. 11 is a section on line I I-I'I of Fig. 9. Fig.-

pair of armature-coils a3 is secured in each slot d a2 of thearmature-core. The commutatorcomprisesA segments b1 corresponding innumber to the number of coils of the armature and each segment isprovided with a slot or notch b2 for vreceiving one of the inner leadsa3 and one of the outer or upper leads from oneof the coils. The outerleads a4, a5. from the pair ofV coils in each armature-slot a2 areconnected to slots in alternate commutator segments. The operation ofthe machine is illustrated for connecting the outer' leads a4,'a5 to thearmature segments after the inner leads a have been connected thereto.In connecting. the leadsv from the armature to the commutator, suitableinsulation is placed around the inner leads lb'between the commutatorand the coils and insulation Vis placed between lthe series of outerleads a4 Aand the series a5. after one of said series has been connectedto the armature segments, as well understood inthe art.

The armature and commutator assembly is removably supported for rotationduring the operation of the machine upon said assembly by a sleeve orhollow head I 'Ivinto which the commutator ts'and a shaft 20 whichengages theouter end of, andcentersthe shaft c of the assembly so thatthe latter will be supported coaxially with said sleeve. Sleeve Il is*carried by a'shaft I6 which is journaled'in ahead-stock I5 adjacent oneend of table I2. kA tail-stock I4 is secured plan, partly in section, ofthe sleeve 'in which 55 adjacent one end'of the table and a head-stock Ion the other end of the table. Shaft 26 is slid- ""q'f slidably mountedand has a limited movement ably mounted in a tail-stock I4 and its innerend is pointed to extend into a socket Vin the outer in a head 42 on arm43. Blade 40 is adapted to pass through slots 25 in sleeve I'I andengage and drive the outerV leads against the bottom leads in the bottomof slots b2 of the commutator. Arm 43 is mounted on a shaft 44 and toswing in a path which will cause blade 40 to operate successivelythrough slots 25 in sleeve I'I. This blade 40 is also adaptedto cut theexcessive por- :101 tion of the leads from the portions secured in ofthe machine. A handle 24 is secured to shaft f( so the latter can beshifted outwardly to permit endwise movement of thecommutator into andout of sleeve I1. Y,

When shaft 20 is shifted outwardly the l'cornmutator can be shifted`endwise into sleeve I1 for performing the lead 'connecting' operationsYcurved edge 4|lb for engaging the lead inwardly of thegcutting edge.Shaft 44 is journaled in a bearing 45 which is'integral with thehead-stock I5. A manually operable pedal 46, which is connected by'alink 41 to arm 43, is adapted to swing and after these have beenperformed the coml the commutator segments and `adapted to regis- Y terwith the notches b2 in said segments topermit the Vtop or. outer leadsfafrom `the armature coils to pass into said notches, respectively. Theouter portions of the sidesof slots are flare-d `or divergent, as at 26,to facilitate the entry of the leads through slots 25 of sleeve I'I andinto notches b2 in the armature segments. Sleeve I'I isdetachablysecured to the inner end of shaft I6 by a bayonet lock .which.comprises a stud 2I fixed to shaft I6 and a slot 29 in the hub 28 ofsleeve 25 which lits around the inner end of shaft I6. A coil-springengages a washer 3I which is held on the outer end of shaft I6 by a nut32 to hold thesleeve I'I longitudinally locked to shaft I6 throughbayonet lock. .An anti-fric'- tion thrust-bearing 33 is interposedbetween `the cuter end of sleeve I1 and the head-stock I5 in which shaftI6 is journaled. A latch 34 is'pivf oted at 35 to a collar 36v which',is mountedand rotatable on the hubV 28 ofsleeve Il and is provided atits free end withan extension 38 which fits in the slots 25 ofsleeveIliand aV tooth 38 which is adapted to pass into any of the notches b2of the4 commutator'barsvto lockjthe commusaid arm to impart operativestrokesto the blade 40. A spring 41a is provided to retract arm 43 andpedal 46. Y Y

In practice, it is desirable to drive or stake each-lead into thearmature segments so they will be effectively Vconnected thereto andsecured therein. AFor v thispurpose a lhigh-speed pneumatic hammer such,for example, as those used for riveting, is provided to impart asuccession of strokes to blade through anvil 4I These hammering strokesalsoserve toimpart blows to the blade for severing the excessive portionfrom the leads. This hammer is Aautomatically controlled to operate theblade 40 after'the latter has forced the leadthroughrslot 25 insleeve I1and approximately toits lowest point in the notch b2 of the commutator.The hammer comprises a cylinder 48 which is xedly mounted in the frontend of arm 43 and a plunger 49 operatedby fluid in said cylinder andadapted to strike and impart blows tothe upper end of anvil 4I to whichblade 46 is secured. Anvil 4I has sufficient lost-motion in head 42 ofarm 43 to cause the head to lower blade 46 with arm 43; duringthedown-stroke of the arm until the leadhas been placed in slot bzrof acommutator segment and to render the anvil operative by plunger 49during the end of the down-stroke of arm 43.

A valve'58 of suitable construction'controls Y the flow of air through aflemme pipe 5| to cylinder 48. VThe casing of valve 5U is stationarilysupported from table I2 by a tube50, to the 1 lowerend of whichfluid maybe supplied from tator and sleeve together for 'conjointrotatiom Y Aspring 39 between latch 34 and collar 36 yieldingly holds the latch in,its operative position. Latch 34, when in its operativev position,serves to lock the armature and the sleeve together for conjointrotation and tov retain the slots b? in the commutator segments inradial registry with the slots 25 in sleeve I-'I during the rotationv ofthe sleeve. Collar-'36j is rotatable on the sleeve to permit the latchto be withdrawn at the end of a series of staking operations for driving,the lead into the notch b2 in whichvit-has. been locked. In connectingthe commutator to sleeve II, the latch is withdrawn and the commutatoris rotated in the sleeve until the slots b2 in the commutator registerradially with the slots 25 in the sleeve` I'I.v The latch is then`released so it will lock the commutator and said sleeve .toget her'forconjoint rotation. A' Mechanism-for driving or staking the leads into`Athe notches b2 of the commutator vcomprises a suitable source.`'Theautomatically closing controlling element of valve 50 ls providedwith an upstanding pin 53 which is adapted Vto'be engaged by a.v stud 52which is carried by the link 41 which operates arm 43. When arm 43 islowered by the operation of pedal 46 andafter blade 40 has been loweredto place the lead in aslot b2 of the commutator, stud 52 will engage anddepress pin 53 to openyvalve 5 0, so that compressed air willV passtecylinder 48 and imparta succession of Vblowsto plunger 49.' During theYinitial portion of the'upstroke of armA 43, stud 52 will release pin 53to permitlvalve 50^to close andv automatically cut der48r.v Y Y v ,Y it

During each downward stroke of arm 43 by pedal 46 and link 41, arm 56will impart an idle backward stroke to link 5'I and pin 59. Duringtheupstroke of' arm43, pin59 willbe operated toV rotate ratchet 58afdistance corresponding to the pitch3between two ratchet teeth, which'will move the next alternate slot 2 5in sleeve lI'Iinto Position-ta beentered bythe blade 40 during-tbe succeeding downward stroke. e

off` thesupply of air t o ,cylin- After a lead has been connected to acommutator segment and its excessive end has been severed therefrom andblade 40 has been Ywithdrawn from sleeve I1, shaft I6, sleeve I1 -andthe assembly comprising the commutator, arman ture and shaft c, arerotated and indexed one step of a sufficient distance to bring'thesecond succeeding slot 25 in sleeve I1 of the slot b2 registeringtherewith into position for securing an outer lead from the same seriesinto the commutator by the next downward stroke of blade 40. Apositioning dogr 6I which is pressed by a spring 64, is slidably mountedin a lug 62 formed on a collar 63 which is normally stationarily held onheadstock I5. The inner end of dog 6I is V-shaped and engagescorresponding V-shaped notches 65 in a wheel 66 to accurately positionthe sleeve I1 and commutator at predetermined points corresponding tothe strokes of the ratchet 56 to position and retain alternate slots 25of sleeve I1 into position for the entry of the blade 40 into suchslots. The-notches 65 Aare spaced apart correspondingly to a pair ofteeth of ratchet wheel 58. At the end of each indexing of the ratchetv58, dog I will accurately position shaft I6 and sleeve I1 for the entryof blade 40 into the slots 25 of sleeves I1.

Notched wheely 56 and ratchet 58 are connected to shaft I6 by a spline1I on which said wheels are slidable so that spring v3| which engagesratchet wheel 58 will be effective to hold the pin 29 longitudinally toprevent the sleeve I1 from becoming unlocked from shaft IS.

In connecting the outer leads to the commutator segments, the leads a4from the outer sides of one coil of the-pair of coils in each of theslots in the armature-core, are successively connected to and secured inalternate slots b2 of the commutator-segments and then the outer leadsa5 from the vouter sides of the other series of coils in the armatureslots are successively connected to the slots b2 in the alternatingsegments of the commutator. Suitable insulation is applied between thetwo series of leads a4 a5 and between the commutator and the adjacentends of the coils. For the purpose of connecting the leads in thismanner, a device is providedfor setting sleeve I1 so'the alternate slots25 will be cooperatively positioned in the path of blade 40 for thesuccessive staking of the outer leads in alternate slots b2 of thecommutator. This device comprises a collar B3 which is rotatably mountedon one end of head-stock I5, a pin 61 which is slidably mounted incollar 63, a spring 68 applied to press 'pin 61 inwardly to project intoeither of hole-s 69, in the head-stock I5 to alternately set thepositioning dog 6I and ratchet 58 for positioning the slots 25 insleeves I1 for inserting the leads into either of the alternate seriesof slots 25 by blade 40. Pin E1 is provided with a handle 61a. pinagainst the force of spring 68 from hole 69 in head-stock I5, androtating the collar 63 to bring pin 61 into alignment with hole 10 andthen releasing the pin,l sleeve I1, commutator and armature will be setso that during the step-bystep rotation of ratchet 58 the blade 40 willbe operative to successively stake the second series of top leads intothe alternate slots b2 into which no leads were secured during theoperations of blade 40 to stake the first series of leads into thearmature-segments. This mechanism exemplifies means for setting thesleeve rotating mechanism for connecting one series of top leads toalternate commutator-segments and after By withdrawing the these havebeen connected, for connecting the second series of top-leads intotheintermediate In practice, it is desired to shape or form vthevportions `of the leads between fthe commutator and the adjacent end ofthe armature-coils to provide a better surface for theinsertion ofinsulation and also for balance. For this purpose, a former 13 isprovided to act upon the leads toward the end of the downward strokes ofblade 4E).v This former has a curved end to conform to the desired`shaping of the lead between the commutator and armature side and issecured to an arm 14 which is pivotally movable around shaft 44 so theformer can swing with theY head 42 and arm 43. Arrn14 is pivoted to acollar 15 which is rotatable on and held against longitudinal movementon shaft-44. Head 42 on arm 43 is adapted to abut against arm 14 so thatwhen arm 43 is lowered the former 13 will be lowered with blade 4I) andbend the lead during the latter part of the downward stroke of blade 40,as illustrated in Fig. 6. Arm 14 is held in abutting relation with guide42 by a spring 16 which is connected to a pin 11 projecting 'downwardlyfrom collar 15. The rear end of arm 14 is pivoted to collar 15 so thatsaid arm can Vbe swung longitudinally of shaft 44 from itsoperativee'ngagement'with'head 42 'and securedunder a to thearmature-segments and the insulation therefor may be applied in aprevious operation. Theoperator will move `centering shaft 2U outwardlyin headstock I4 suiciently to permit commutator b to be inserted endwiseinto sleeve I1 and the projecting end of the shaft c to extend into theshaft I When the commutator has been inserted in the sleeve, the leadsa4, a5 will lap or project longitudinally over the sleeve I1. Shaft 20,when released, will be shifted by weight-2| into engagement with one endof armature shaft c and hold the commutator in sleeve I1 so that theassembly will be supported coaxially with sleeve I1 and shaft I6. Duringthe insertion of the commutator in sleeve I1, latch 34 will be heldoutwardly. When the commutatorhas been placed in the machine, lthecommutator will be rotated in the sleeve to bring the-slots b2 in thearmature-segments. into radial registry with the'slots 25 in the sleeveand latch 34 will be released so it will pass through one of the slots25 and project into the registering slotl b2. This will lock thecommutator and armature to thesleeve I1 for rotation therewith. Spring30 will press sleeve I1 endwise to retain the bayonet-catch 28, 29 soitwill lock shaft I6 and sleeve I1 against inward longitudinal movement.The operator will then-release arm 14 from hook 19 and swing it intoabutting relation with head 42 of arm 43. The operator will thenmanually press the proper top lead a4 into the slot 25Yinto which theblade'40 will pass when it is lowered and then'depress pedal 45 andthereby impart a downward stroke to arm 43. The

pin 53 toropen valvef50'forsupplying air to operatethe pneumatic plungerIl!) and impart a rapid succession of blows to the anvil 4|. These blowswill` cause the blade 4l) to sever. the-excess y wire-from the lead andto forcibly drive the lead as -far aspossible toward the bottom Vof slotbZ and thus complete the connecting or. staking operation. As thebladel'approaches the jlower end-of its` stroke, -former "13 will engagethe portion Yof the inserted lead between the commutator .andthe end`'of thearmature andshape said'portionras desired Yand illustrated inFig. 6. 'The pedal is thenreleasedand arm 43. is raised to its normalposition.A DuringV the downstroke of arm 43, arm 56 will shiftlink` 51rearwardly a Vdistance slightly greater than that between alternateteeth on ratchet 58 and slots 25 in sleeve l1. During the upstroke ofrarm 43-impartedby spring 60, arm 56 and link Vtilwill advance theratchet V58 twoV teeth. This advance of f the ratchetwill rotate thesleeve I1 and the commutator to bring the second next slot25 andY slotb1 into the path-of blade 40, this feeding andr indexing servingto, passthe intermediate-,slot 25 in sleeve I1. These operations ar continueduntil the entire series of leads a4 has been secured in the slots b2 of-alternate commutator-segments. 'I'he former may then, if desired, Vbemoved out of abutting relation: with arm 43 and latched under hook 19.`An insulating collar or other insulation willthen beplaced around the iouter leads a4 which have been secured in the armature-segments. AThemachine isy then set for connecting` the leads a5 to ther'intermediatesegments of the commutator by adjustment of notched wheel 66 intoposition for step-by-step strokes which willV bring the slots for' saidleads successively into operativeV relation 'with the blade!!! duringthe downstrokes of arm 43.

collar 63 on headstock l5 `to rotate ratchet 58 and For that purpose,pin-6`l will be disengaged from hole 69 and collar 63, notched wheel 66,ratchet 58, shaft I6 and sleeve I-l will be rotated relatively to thehead-stock I5, and pin 61 Will be locked in hole 10, so that thealternate slots into which no leads have'been inserted will, during thestepby-step advances of the ratchet 58, be successively broughtinto-position for the entry of the blade 40 into the alternate slots forthe-insertion of' the leads a2. Theoperation ofjpedal 56 then continuedto successively insertl the leads ail in` the slots b2 and to'severtheexcessive ends'from the leads and form the leads as beforedescribed.Latchlr34 is `then disengaged from*Y the commutator and withdrawn fromthe slot25 lnsleeve l1 of the commutator. Y

The invention is not togjbe understood as re'- stricted to the detailsset forth, since these may be modied-within the scope ofthe appendedclaims, without departing fromthe spirit and'l segments and anarmature', comprising coils-and leads 'extending from the coils, said.:supporting means comprising a sleeve fitting' around the commutator andhaving slots therein adapted to p register with the slots in theVsegments, means for successively securing leadsinthe slots inthesegments, and mechanismffo'r rotatingthe 'sup- 5 5 so a lead can beinserted in the registering slot b2 porting means step-by-.step toAsuccessively bring `tl'ieusecuring means. I 2 In ,a machine of thecharacter described, the combination of` means for rotatively supportingan-asvsembled commutator having slotted segments and anV armaturecomprising coils iand leads Yextending fromthe coils, said supportingmeans comprising a sleeve fitting around `the commutator and havingslots therein adapted to register withrthe lslots-'in the segments,means for successively-securing leads in the slots in the segments,andmvechanism for rotating the supporting means step-by-step tosuccessively bring alternate slots in-jthe sleeve -into position for theconnection of a lead to a commutator segment. y

3, Ina machine of the character described, the combination of means forrotatably supporting ari-assembled commutator having slotted segmentsand an armature comprising'coils and leads extending from-the coils,said supporting meansY comprising a sleeve tting around thecommutatorand having-slots therein adapted to register withthe slots inthe segments, a blade for successively securing leads in the slots inthe segments, mechanism for imparting strokes to the blade, andmechanism also operated by the mechanism for imparting strokes to theblade for. rotating theV supporting means step-by-step to bringalternate lslots in the sleeve into oper- 'ative position for theconnection of a leadto a commutator segment forA-each'operative strokeof theblade. i 5

' 4. Ina machine ,of-the character described, the combination of meansfor rotatably support- .ingan assembled commutator having slottedsegments and Van armature comprising coils and leads extending from thecoils, said supporting means lcomprising a sleeve` tting around thecommutator and provided with slots registering with ythe slots in. thesegments, means for successively connecting leadsv placed in the slotsof the sleeve to the commutator segments, means for rotating the'sleevestep-by-step to bringalternate slots in the sleeve into position fortheconnectiorrofthe leads to the segments, and means for adjusting theadvancing mechanism to rotate the sleeve to Vposition the commutator for,inserting leads into intermediate segments. 5 Inamachineof `thecharacter described, the .combination ofV means for rotatably supportinganl assembled commutator having slotted seg- Y Athe/slots in the sleeveinto operative position for ,ments and an armature comprising coils and.

leadsVV extending from-the coils, means for rotating said supportingmeans step-by-step to bring slots in the segments into position fortheconnection of the leads to the segments, a blade for inserting leadsinto the segments, reciprocating .means for operatingv the blade, aformer situated in the-path of -reciprocation of said reciprocatingoperating means fand operable by contact therewith forshaping-th eleadsv between the commutatorjand the adjacent end of the armature, andkmeans for movably supporting the former so it may be so situated ormoved out of said path and thereby be disengaged from the reciprocatingkoperating means. A

Y d :ln ai machine of-'thecharacter described, the combination ofmeans'for rotatably supportinganassembled commutator having slottedsegments andan armature comprising coils and leads extending from Vthecoils, said supporting means comprising a sleeve Ihaving slotsregistering with ,the slotsin the segments,a;blade for successivelyconnecting the leads to the segments, an arm on which the blade issupported, means for manually imparting strokes to the arm to operatethe blade, means for rotating the sleeve step-by-step to successivelybring slots in the Sleeves and segments into operative relation with theblade, and a former for shaping the leads adjacent the commutator,operable by said arm, and pivotally mounted so it may be swung away fromthe arm.

7. In a machine of the character described, the combination of means forrotatably supporting an assembled commutator having slotted segments andan armature comprising coils and leads extending from the coils, amovable arm, manually operated means for imparting' strokes to the arm,a blade carried by the arm for successively placing the leads in theslots in the segments, a pneumatic hammer mounted on the arm forimparting a rapid succession of blows to the blades to drive the leadsfurther into the slots in the segments after they have been placed inthe slots, a valve for controlling the hammer, and means on said armadapted to contact said Vvalve after a predetermined movement of saidarm for startingA the operation of said pneumatic hammer.

8. In a machine of the character described, the combination of means forrotatably supporting an assembled commutator having slotted segments andan armature comprising coils and leads extending from the coils, amovable arm, manually operated means for imparting strokes to the arm, ablade carried by the arm for successively placing the leads in the slotsin the segments and provided with a cutting edge for severing theleadsin the slots, a pneumatic hammer mounted on the arm for. impartinga rapid succession of blows to the blade to drive the leads further intothe slots in the segments after they have been placed in the slots andto sever ends from the leads inthe slots, a valve for controlling thehammer, and means on said arm adapted to contact said valve after apredetermined movement of said arm for starting the operation of saidpneumatic hammer. JASPER F. CULLIN.

